Decentralized I/O Solution in Ex Zone for H2-Fueling Station

Faster commissioning and better scalability for hydrogen infrastructure thanks to IP67 remote I/O technology for all ATEX zones

The automation technology for hydrogen refueling stations has special requirements due to the high pressures and explosive hydrogen gas involved. The fueling stations also have to be built and commissioned quickly in order to meet the rapidly increasing demand. 

Decentralized IP67 I/O concept for signals up to Zone 0

A manufacturer of hydrogen refueling stations is solving these challenges with Turck's decentralized IP67 concept for ATEX Zones 1 and 2. The many analog and digital signals of each buffer storage tank are connected directly at the storage tank on IP67 I/O modules for Zone 2.

Your Benefits

  • Faster commissioning thanks to decentralized I/O concept up to ATEX zone 1
  • Improved flexibility for adding more H2 fuel pumps and buffer storage
  • Less manual wiring work during commissioning
  • Pre-testing in production easier and more reliable, as no rewiring is required at the end user's site

  • The hydrogen fueling station provides different pressures for trucks and cars

  • Scalability: thanks to the modular concept, more storage buffers can be added more easily

  • The only I/O concept that can connect Zone 1 signals without a control cabinet

IP67 interface modules of the IMC series make it possible to connect intrinsically safe sensors for ATEX Zone 0 and 1. In this way, the sensors and actuators from the different ATEX zones can be connected to the Profinet controller with one I/O system. The time-consuming installation of large control cabinets at the buffer storage tanks is no longer necessary. 

Modularization simplifies expansion

Later expansions are much easier to implement, since additional buffer storage systems just require a power supply and an Ethernet communication to be added to the main controller. The control program also has a modular design so that any subsequent expansion does not require extensive programming work either. 

Safety signals integrated in IP67 concept

The safety concept is also decentralized: emergency stop signals and other safety signals were implemented on the TBPN  IP67 safety modules which are located directly on the buffer storage unit. All components are designed for use in outdoor areas with a temperature range of -20 to 65 degrees. Turck ensured fast and simple commissioning with an adapted connection technology concept. This means overall that fewer electrical engineers are needed for commissioning support today than with the previous point-to-point concept using multicore cables and passive junctions.  

Comprehensive consulting and support ensure successful commissioning 

In this application, Turck not only supported the customer with the products, but also with extensive consulting, and developed together with the customers the I/O concept for modularizing their hydrogen filling stations. Turck experts on site were also able to contribute to the success of the solution during commissioning.

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